Supply Chain. cinagement. IStlGS USO OS.S. Fourth Edition. Donald J. Bowersox David J. Closs M. Bixby Cooper John C. Bowersox.

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1 USO OS.S Supply Chain IStlGS cinagement Fourth Edition Donald J. Bowersox David J. Closs M. Bixby Cooper John C. Bowersox Michigan State University Me Graw Hill

2 About the Authors iv Preface v PART ONE MANAGEMENT 1 Chapter 1 21st-century Supply Chains 2 The Supply Chain Revolution 4 Why Integration Creates Value 5 Generalized Supply Chain Model 6 Information System Functionality 7 Supply Chain Information System Modules 10 Enterprise Integration and Administration 11 Enterprise Supply Chain Operations 12 Enterprise Planning and Monitoring 13 Communication Technology 14 Consumer Connectivity 14 Integrative Management and Supply Chain Processes 14 Collaboration 16 Enterprise Extension 17 Integrated Service Providers (ISPs) 17 Responsiveness 19 Anticipatory Business Model (Push) 19 Responsive Business Model (Pull) 20 Postponement 21 Barriers to Implementing Responsive Systems 23 Financial Sophistication 23 Cash-to-Cash Conversion 24 Dwell Time Minimization 24 Cash Spin 25 Globalization 25 Summary 26 Study Questions 27 Challenge Questions 27 Chapter 2 Logistics 28 The Logistics of Business Is Big and Important 29 The Logistical Value Proposition 30 Service Benefits 30 Cost Minimization 32 Logistics Value Generation 32 The Work of Logistics 33 Order Processing 33 Inventory 34 Transportation 35 Warehousing, Materials Handling, and Packaging 36 Facility Network Design 3 7 Logistical Operations 38 Inventory Flow 38 Information Flow 40 Logistical Integration Objectives 40 Responsiveness 41 Variance Reduction 41 Inventory Reduction 41 Shipment Consolidation 41 Quality 42 Life Cycle Support 42 Logistical Operating Arrangements 42 Echelon 43 Direct 43 Combined 44 Flexible Structure 45 Supply Chain Synchronization 47 Performance Cycle Structure 48 Performance Cycle Uncertainty 50 Summary 52 Study Questions 53 Challenge Questions 53 Chapter 3 Customer Relationship Management 54 Customer-Focused Marketing 55 Transactional versus Relationship Marketing 56 Supply Chain Service Outputs 57 Customer Service 59 Availability 59 Operational Performance 61 Service Reliability 62 The Perfect Order 63 Basic Service Platforms 64

3 Customer Satisfaction 64 Customer Expectations 65 A Model of Customer Satisfaction 65 Increasing Customer Expectations 68 Limitations of Customer Satisfaction 69 Customer Success 70 Achieving Customer Success 71 Value-Added Services 72 Developing Customer Relationship Strategy 73 Framework for Strategic Choice 73 Customer Relationship Management Technology 75 Summary 76 Study Questions 77 Challenge Questions 78 Chapter 4 Procurement 79 Procurement Objectives 80 Continuous Supply 80 Minimize Inventory Investment 80 Quality Improvement 81 Supplier Development 81 Access Technology and Innovation 81 Lowest Total Cost of Ownership 81 Procurement Strategy 83 Insourcing versus Outsourcing 83 Alternative Procurement Strategies 84 Procurement Strategy Portfolio 87 Supplier Selection and Assessment 89,' Supplier Audits 89 Supplier Development 90 Monitoring Performance 90 Supplier Certification 91 E-Commerce and Procurement 91 Logistical Interfaces with Procurement 92 Just-in-Time 93 Procurement of Logistics Services 93 Performance-Based Logistics 94 Summary 94 Study Questions 95 Challenge Questions 95 Chapter 5 Manufacturing 96 The Quality Imperative 97 Dimensions of Product Quality 97 Total Quality Management 99 Quality Standards 100 Manufacturing Perspectives 100 Brand Power 100 Volume 101 Variety 101 Constraints 102 Leadtime 103 Manufacturing Strategy 103 Basic Manufacturing Processes 104 Matching Manufacturing Strategy to Market Requirements 106 Alternative Manufacturing Strategies 106 Total Cost of Manufacturing 108 Contemporary Manufacturing Developments 109 Mass Customization 109 Lean Systems 110 Flexible Manufacturing 111 Six Sigma 112 Requirements Planning 113 Design for Manufacture 113 Design for Logistics 114 Summary 114 Study Questions 115 Challenge Questions 115 Chapter 6 Integrated Operations Planning 116 Supply Chain Planning 117 Supply Chain Visibility 117 Simultaneous Resource Consideration 117 Resource Utilization 118 Supply Chain Planning Applications 118 Demand Planning 118 Production Planning 119 Logistics Planning 119 Inventory Deployment 120 Sales and Operations Planning 121 S&OP Process 121 Making S&OP Work 124 APS System Overview 126 APS System Components 127 Supply Chain Planning Benefits 129 Supply Chain Planning Considerations 130 Integrated Business Planning 131 Supply Chain Planning Summary 131 Collaborative Planning, Forecasting, and Replenishment 132 Forecasting 133 Forecasting Requirements 134 Forecasting Components 135 Forecasting Process 137

4 Forecasting Techniques 139 Forecasting Accuracy 143 Summary 145 Study Questions 145 Challenge Questions 146 PART TWO OPERATIONS 147 Chapter 7 Inventory 148 Inventory Functionality and Definitions 149 Inventory Functionality 149 Inventory Definitions 151 Inventory Carrying Cost 155 Capital 155 Taxes 155 Insurance 155 Obsolescence 146 Storage 156 Planning Inventory 156 When to Order 156 How Much to Order 157 Managing Uncertainty 162 Demand Uncertainty 162 Performance Cycle Uncertainty 166 Safety Stock with Combined Uncertainty 166 Estimating Fill Rate 168 Dependent Demand Replenishment 171 Inventory Management Policies 171 Inventory Control 172 Reactive Methods 174 Planning Methods I75 Collaborative Inventory Replenishment 180 Inventory Management Practices 181 Product/Market Classification 182 Segment Strategy Definition 183 Policies and Parameters 183 Summary 184 Study Questions 184 Challenge Questions 185 Chapter 8 Transportation 186 Transport Functionality and Participants Functionality 187 Participants From Regulation to a Free Market System 190 Transporation Modal Structure 191 Rail 193 Truck 194 Water 196 Pipeline 196 Air 197 Modal Comparative Characteristics and Capabilities 198 Infrastructure in Crisis 198 Specialized Transportation Services 199 Package Services 199 Intermodal 201 Nonoperating Intermediaries 202 Transportation Economics and Pricing 203 Economy of Distance 203 Economy of Weight 203 Economy of Density 204 Other Pricing Factors 204 Costing Freight 205 Pricing Freight 206 Transportation Management 212 Operational Management 212 Consolidation 213 Negotiation 215 Control 215 Auditing and Claim Administration 216 Documentation 217 Bill of Lading 217 Freight Bill 219 Shipment Manifest 219 Product Pricing and Transportation 219 F.O.B. Pricing 219 Delivered Pricing 220 Pickup Allowances 221 Summary 221 Study Questions 222 Challenge Questions 222 Chapter 9 Warehousing 223 Strategic Warehousing 224 Economic Benefits 225 Service Benefits 230 Warehouse Operations 231 Handling 231 Storage 233 Warehouse Ownership Arrangements 235 Private 235 Public 236

5 Contract 236 Network Deployment 237 Warehouse Decisions 237 Site Selection 23 7 Design 238 Product-Mix Analysis 239 Expansion 239 Handling 239 Layout 240 Sizing 241 Warehouse Management Systems (WMS) 241 Yard Management Systems (YMS) 243 Accuracy and Audits 244 Security 244 Safety and Maintenance 245 Summary 246 Study Questions 246 Challenge Questions 247 Chapter 10 Packaging and Handling 248 Packaging Perspectives 248 Packaging for Handling Efficiency 251 Package Design 251 Unitization 252 Communication 254 Handling 255 Basic Handling Considerations 255 Mechanized Systems 256 Semiautomated Systems 25 7 Automated Systems 259 Information-Directed Systems 263 Special Handling Considerations 264 Summary 266 Study Questions 266 Challenge Questions 266 PART THREE DESIGN 269 Chapter 11 Global Supply Chains 270 Global Economies 270 Global Supply Chain Integration 271 Logistics in a Global Economy 272 Globalization Strategies 272 Managing the Global Supply Chain 276 Global Sourcing 280 Rationale for Low-Cost-Country Sourcing 280 Challenges for Low-Cost-Country Sourcing 281 Guidelines for Sourcing 282 Summary 283 Study Questions 283 Challenge Questions 283 Chapter 12 Network Design 285 Enterprise Facility Network 286 Spectrum of Location Decisions 287 Local Presence: An Obsolete Paradigm 287 Warehouse Requirements 288 Procurement Drivers 288 Manufacturing Drivers 289 Customer Relationship Drivers 290 Warehouse Justification 291 Systems Concept and Analysis 291 Total Cost Integration 292 Transportation Economics 292 Inventory Economics 295 Total Cost Network 300 Formulating Logistical Strategy 301 Cost Minimization 302 Threshold Service 302 Service Sensitivity Analysis 304 Establishing Strategy 306 Other Considerations in Logistics Network Design 307 Summary 308 Study Questions 309 Challenge Questions 310 Chapter 13 Operations Analysis 311 Planning Methodology 311 Phase I: Problem Definition and Planning 312 Feasibility Assessment 312 Project Planning 318 Phase II: Data Collection and Analysis 320 Assumptions and Data Collection 320 Analysis 323 Phase III: Recommendations and Implementation 325 Recommendations 325 Implementation 326

6 XII Contents Supply Chain Operations Analysis Methods and Techniques 327 Design Decisions 327 Design Logic 328 Inventory Decisions 334 Transportation Decisions 336 Freight Lane Analysis 338 Inventory Analysis 339 Summary 341 Study Questions 341 Challenge Questions 342 PART FOUR ADMINISTRATION 343 Chapter 14 Collaboration 344 Logistical Organization 345 Functional Aggregation 345 A Shift in Emphasis from Function to Process 347 Development of Collaborative Relationships 351 Collaborative Relationships and Dependency 352 Developing Trust 353 " Risk, Power, and Leadership 355 Supply Chain Collaborative Framework 356 Relationship Management 360 Initiating 360 Implementing 361 Maintaining 362 Terminating 363 Summary 364 Study Questions 364 Challenge Questions 365 Chapter 15 Performance Measurement 366 Measurement System Objectives 366 Operational Assessment 367 Functional Perspectives 368 Measuring Customer Relationships 372 Determining Appropriate Metrics 374 Supply Chain Comprehensive Metrics 3 75 Benchmarking 3 77 Information Technology and Measurement 378 Financial Assessment 379 Cost-Revenue Analysis 3 79 Strategic Profit Model 383 Requirements for Financial Reporting 387 Summary 389 Study Questions 390 Challenge Questions 390 Chapter 16 Risk and Sustainability 391 Evolving Responsibilities of Supply Chain Professionals 391 Processes and Resources 394 Product Complexity 394 Outsourcing 395 Risk and Security Management 395 Regulation 397 Financial and Taxation 397 Security 398 Sustainability 402 Environmental 403 Ethical 404 Educational 405 Economic 406 Supply Chain Sustainability Examples 407 Summary 414 Study Questions 415 Challenge Questions 415 Epilogue 417 Problems 419 Cases 431 Index 475

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